KR20000022391A - Strand - Google Patents

Abstract

PURPOSE: A strand with a periodic flat spots is to provide unique properties useful in packaging the strand for shipping to customers. CONSTITUTION: The strand has a primary cross-sectional shape, and periodic flat spots with a flat cross -sectional shape which is more elongated than the primary cross-sectional shape. The primary cross-sectional shape of the fill yarn has an aspect ratio within the range of from about 1: 1 to about 6: 1, and the flat cross-sectional shape has an aspect ratio greater than about 6: 1 to about 50: 1. The width of the flat spots is within the range of from about 5 to about 20 times the width of the primary cross-sectional shape. The period of the periodic flat spots is within the range of from about 0.5 to about 3 meters and the length of the periodic flat spots is within the range of from about 1 to about 5 cm.

Description

Strand

Mineral fibers are used in a variety of products. The fibers are used as reinforcements in products such as plastic matrices, reinforcement papers and tapes, and woven products. During the process of forming and collecting the fibers, many fibers are bundled into strands. Several strands may be gathered to provide a structural support to a product, such as a molded plastic product, to form a roving used to reinforce the plastic matrix. The strands can be woven to form a fabric, or collected as a fabric in a random pattern. Each strand may be formed by collecting glass fibers or may be composed of fibers of other materials, such as other inorganic or organic polymeric materials. A protective coating or size may be applied to the fibers, such that when the fibers are collected to form a single strand, the fibers can be crossed without breaking. By protecting in size, the strands can be handled in various manufacturing processes such as weaving. Where fibers are used in industrial applications, size promotes bonding between strands and plastic matrices. The size may also include a binder that bonds the fibers together to form an integral strand.

Generally, continuous fibers such as glass fibers are mechanically drawn from a feeder or molten glass. The feeder has a bottom plate or bushing with 200 to 10,000 holes. In the forming process, the strand is wound around a rotating drum or collet to form a package. The finished package consists of a single long strand. The package is preferably wound so that the strands can be easily unwound. It is known that a winding pattern consisting of a series of spiral courses placed on a collet forms a package that can be easily released. If the strands are wet with the size material applied, such a helical pattern prevents loops or wraps of adjacent strands from joining together. The spiral course is wound around the collet when the package begins to form. Subsequent courses lie on the outer surface of the package, continuously increasing the diameter of the package until the winding is finished and the package is removed from the collet.

A strand reciprocator guides the strand reciprocally longitudinally across the outer surface of the package, stacking each successive course. Spiral wire strand oscillators are known as strand reciprocating engines. The spiral wire strand oscillator is composed of a rotating shaft including two outboard wires of a substantially spiral shape. The helical wire strikes the running strand and orients the strand back and forth along the outer surface of the package. In addition, the shaft is moved longitudinally such that a rotating helical wire crosses the package surface, stacking strands on the package surface. During the formation of the package, the spiral wired strand oscillator is not in contact with the package surface. Although the spiral wire strand oscillator produces a package that can be easily unwound, the package does not have an angular edge. Packages with angled edges may have larger diameters than packages with rounded edges. Thus, it is desirable to form cylindrical packages of angular edges and large diameters.

Known strand reciprocating engines that produce angled edges and cylindrical packages include a spiral groove, a cam follower disposed within the groove and a strand guide attached to the cam end. As the cam rotates, the cam termination and strand guides reciprocate the strand longitudinally across the outer surface of the rotating package, thereby stacking each successive course. The rotatable cylindrical member or roller bail contacts the outer surface of the package when the outer surface of the package rotates, and the strands laid on the last course when the strand guides change direction at the edge of the package. Keep it in place. The roller bale rotates because the roller bale contacts the surface of the rotating package, and the speed of the roller bale surface is generally the same as that of the package surface. Another type contacts the strand guide itself with the package, temporarily holding the strand at the edge of the package.

To improve productivity, several packages are formed simultaneously on a single collet. Separate strands are formed for each package, and the separate strand reciprocating engines reciprocate each strand to produce packages simultaneously. While maintaining contact between the roller bale and the package surface, as the package radius increases, the strand reciprocator is mounted on an arm that moves the strand reciprocator in the direction away from the collet. The fiber forming process is controlled, including the breakdown temperature, to keep the fiber diameter constant throughout the collecting process and to maintain similar package radius growth rates for each package.

However, because process deviations occur, small deviations occur in the package size with the collet during the collection process. Because of the difference in the relative radius of the package on the collet, the roller bales are occasionally spaced from the package surface. When the roller bale is spaced away from the package surface, the rotation speed of the roller bale begins to decrease. When the surface of the roller bale is in contact with the package surface again, the rotational speed of the roller bale increases until the rotational speed of the roller bale surface is equal to the rotational speed of the package surface. Due to bearing friction and inertia of the roller bale, it takes time for the roller bale to return to its original speed. Due to the speed difference between the package surface and the surface of the roller bale, the roller bale slides off the package surface while the rotation of the roller bale is restored to its original speed. If the inertia is too large, a roller bale will produce a sliding friction force that breaks the fibers of the strand. In addition, slippage may occur during the start of an operation in which the rotational speed of the collet is increased. Broken strand fibers are separated from the strand as the strand is wound on the package, and wrap around the rotating roller bale, which creates entanglement that may ruin the package.

It is desirable to produce strands with improved packaging, dispensing and weaving properties.

The present invention relates to the production of fiberglass strands and to the packaging, dispensing and weaving of yarns for reinforcement or decorative materials.

1 is a schematic elevation view of an apparatus for forming, collecting and winding fiber strands in accordance with the principles of the present invention.

FIG. 2 is an enlarged schematic elevation view of the strand reciprocating engine shown in FIG. 1. FIG.

FIG. 3 is a schematic sectional elevational view of the apparatus of FIG. 2 taken along line 3-3. FIG.

FIG. 4 is a cross-sectional view of the roller bail assembly of FIG. 1. FIG.

5 is a schematic diagram showing an embodiment of the invention in which several packages are wound simultaneously.

It is a schematic top view which shows the yarn of this invention.

It is a schematic elevation view which shows the yarn of this invention.

FIG. 8 is a schematic cross-sectional diagram cut along the line 8-8 of FIG. 7. FIG.

9 is a schematic cross-sectional diagram cut along the line 9-9 of FIG. 7.

10 is a schematic elevation view showing a package of a yarn according to the present invention.

11 is a schematic elevation view of an air jet loom used in the method of the present invention.

12 is a detail view of the air jet of the loom shown in FIG. 11.

Fig. 13 is a schematic diagram of the fabric of the present invention in which the different wefts form a repetitive pattern.

14 is a schematic diagram of another fabric of the present invention in which a repetitive pattern is formed in the fabric by means of differentiated wefts.

Figure 15 is a schematic diagram showing the fabric of the present invention in which differentiated wefts are generally aligned according to a particular warp such that a longitudinal pattern is formed in the fabric.

FIG. 16 is a schematic showing the fabric of the present invention with differentiated wefts disposed generally at random intervals throughout the entire fabric. FIG.

According to the present invention, a strand of individual filaments is provided, said strand having a main cross-sectional shape and a periodic flat portion of a flat cross-sectional shape extending longer than the main cross-sectional shape. Strands with periodic flats provide useful and unique properties in packaging strands for loading to consumers. The strands also provide advantages in subsequent manufacturing processes, such as weaving processes.

The main cross sectional shape of the fill yarn preferably has an aspect ratio in the range of about 1: 1 to about 6: 1, and the flat cross sectional shape preferably has an aspect ratio of greater than about 6: 1. More preferably, the aspect ratio of the flat cross-sectional shape is greater than 20: 1. Most preferably, the aspect ratio of the flat cross-sectional shape is in the range of about 6: 1 to about 50: 1. In a preferred embodiment of the present invention, it is preferred that the width of the flat portion is in the range of about 5 to about 20 times the width of the main cross-sectional shape.

In certain embodiments of the present invention, the period of the periodic flat portion is in the range of about 0.2 to about 6 m, more preferably in the range of about 0.5 to about 3 m.

In another preferred embodiment of the present invention, the length of the periodic flats is in the range of about 0.5 to about 10 cm, more preferably in the range of about 1 to about 5 cm.

Improved methods of manufacturing strands with periodic flat portions and improved control methods of the manufacturing process for obtaining certain characteristics in the strands have been developed. The method of the present invention includes the steps of winding the strand to the package by rotating the collet, the step of crossing the strand from one end of the package to the other end, the step of contacting the roller bale and the package at both ends of the package, and applying pressure to the package with the roller bale. And applying the strand to flatten the strand as it is wound at the edge, thereby creating a strand having a periodic flat portion, and controlling the flattening of the strand by controlling the pressure of the roller bale on the package.

In certain embodiments of the invention, the roller bale is spaced apart from the collet during winding the strand to accommodate the increase in the diameter of the package. The pressure applied to the package by each roller is preferably in the range of about 2 to about 10 pounds (0.91 to 4.5 kg), more preferably in the range of about 3 to about 6 pounds (1.4 to 2.7 kg).

In another embodiment of the present invention, the process of planarizing the strands is controlled by controlling the transverse velocity of the strands. By using a process of controlling the transverse velocity of the strand to determine the length of the strand wound on the package while the strand is at the edge, the length of the flat portion can be controlled. To control the period of the flats, the transverse speed of the strands can be varied while winding the strands. In certain embodiments of the present invention, the transverse speed of the strands is controlled to provide a constant period between flat portions in general.

In another embodiment of the invention, the strand is traversed by the reciprocating motion of the strand reciprocating engine mounted to move along the spiral groove in the rotary cam, the spiral groove having a curved end at each end of the cam, the transverse of the strand. The speed is controlled by forming the shape of the curved end of the spiral groove.

In the air jet loom weaving process, improved methods of weft insertion have been developed. The weft is propelled from the insertion side of the loom to the outlet side by one or more air jets. The yarns have strands of each filament, the strands having a periodic cross section of a major cross-sectional shape and a flat cross-sectional shape extending beyond the main cross section. The flats provide increased drag for propulsion by air jets.

In a particular embodiment of the invention, the period of the flat portion is synchronized with the length of the weft yarn required for the air jet loom. The flats may be synchronized to allow the flats to pass through the air jet at an early stage of pushing the wefts across the air jet loom, thereby facilitating propulsion of the wefts across the loom. Because of this, it is possible to operate the loom with a lower air jet pressure.

Woven fabrics have been developed that provide unique appearance by having different yarns in various locations throughout the fabric. The fabric consists of a weft and a warp, the weft being a strand of each filament, the strand having a periodic cross section of a major cross-sectional shape and a flat cross-sectional shape extending longer than the main cross section. The effect of the flattening is to create a differentiated weft in the woven fabric. In certain embodiments of the invention, the differentiated wefts are brighter in color than the remaining wefts. In another embodiment of the present invention, the differentiated weft produces more reflection than the remaining wefts.

Differentiated wefts are wider than residual wefts, and preferably have an average width in the range of about 125 to about 300% of the average width of the remaining wefts. It is more preferred to have an average width in the range of about 125 to about 175% of the average width of the remaining wefts.

In a preferred embodiment of the present invention, the average length of the differentiated wefts falls within the range of about 0.5 to about 10 cm, preferably within the range of about 1 to about 5 cm.

In certain embodiments of the present invention, the differentiated wefts are generally not uniformly spaced throughout the fabric.

In another embodiment of the invention, the differentiated wefts are generally aligned to a particular warp, forming a longitudinal pattern along the length of the fabric.

In another embodiment of the invention, the differentiated weft forms a repeated pattern in the fabric.

Improved yarn packages have been developed that improve stability and can be pulled out of the yarn without breaking the package. The package is supported by itself and is wound in a spiral form. The yarns in the package are strands of each filament, the strands having a periodic cross section of a major cross-sectional shape and a flat cross-sectional shape extending beyond the main cross section. The package has an edge portion located about the axis at the end of the package, and the flat portion is located in the edge portion of the package. The package is wound in a spiral course and sized to the yarn. The size combines each course with the adjacent course, and the flat part exhibits a stronger bond than the part having the main cross-sectional shape of the yarn. The average force required to unwind the yarn from the package is in the range of about 5 to about 100 g. The package has an axial length that falls within the range of about 8 to about 40 cm and preferably has a diameter within the range of about 20 to about 50 cm.

1 and 2 show a device for forming, collecting, and winding strands, wherein the fiber 10 is drawn from a plurality of orifices 11 in the bushing 12 and is stranded by the focusing member 16. 14). Suitable sizes for fiber coating are applied to the fibers by any suitable means, such as size applicator 18. The strand is wound around the rotating collet 220 to form a cylindrical package 19. The package formed from a single long strand has an angled edge portion 20a and a central portion 20b between the angled edge portion. It has a radial outer surface 20. In general, the angled edge portion 20a is perpendicular to the package end 20c. The length of the outer surface of the cylindrical package is preferably within the range of about 10 to about 40 cm. However, it may be longer or shorter depending on the application The collet is adjusted to rotate around the axis of rotation 23 by any suitable means, such as motor 24. Any suitable package, such as cardboard tube 26 The core material may be placed on the collet to receive the strand package.

FIG. 2 shows the twisted pipe 30 which guides the strand 14 laterally back and forth and builds up in the course 44 on the package surface.

The strand reciprocating engine includes a cylindrical cam 32 having a helical groove 34. The cam is mounted for rotation and is preferably made of a hard material, such as stainless steel, but any suitable material may be used. The strand reciprocating engine further comprises a cam follower 36 disposed in the groove 34. The cam follower extends outward from the cam and a strand guide 38 is attached to the end. The cam follower is preferably made of plastic or nylon, but any suitable material may be used. Notches 40 are formed in the strand guides to hold the strands 14. As the cam rotates, the cam follower follows the helical groove, so the strand guide moves laterally across the package surface.

Referring to FIGS. 2 and 3, the strand reciprocating engine may include a roller bale assembly 42 for retaining the strand course 44 at the edge portion 20a of the package surface when the strand guide 38 changes direction. It further includes. The roller bale assembly includes a pair of spaced or separated rollers 46. Generally, the rollers have a cylindrical edge end 46a and a tapered inner end 46b. The cylindrical edge end is in contact with the package surface at the edge portion 20a. The inner end of the tapered shape extends from the edge end to the center of the package surface 20b. The roller does not contact the surface of the package at the central portion 20b of the package. Each roller 46 is independently mounted by the mounting portion 48 for rotation. One or more bearings (not shown) are positioned between the roller bale and the mounting to reduce the friction so that the roller bale can rotate freely. Although the roller bale is shown mounted at the edge end and the inner end, the roller bale may be mounted in a cantilever manner where it is mounted only at one end. Each roller is made of a hard material, such as stainless steel, but any suitable material may be used. It is preferred that the weight of each roller is approximately 50 g, but may be heavier or lighter depending on size and application. Hollow conditions are desirable to minimize weight and inertia, but may not. Each roller is preferably 2 cm in length, but may be longer or shorter depending on the application.

The separated roller bale is generally coaxial and may be arbitrarily suitably oriented, but generally contacts the package surface along a line 52 parallel to the axis of rotation 23 of the package. Using a roller bale with a length of 2 cm, the contact length between the roller bale and the typical package surface is approximately 10 to about 50% of the package outer surface length. Depending on the application, the contact length between the roller bale and the package surface may be longer or shorter.

As shown by line 53 of FIG. 4, the package rotates during the winding process. As the package is formed, the radius 54 increases. To accommodate the increasing package radius, strand reciprocating engine 30 is mounted on the arm 56. To accommodate the increasing package radius, the arm is spaced along a 63 line to maintain proper contact between the surface of the roller and the package surface and to prevent the strand course 44a from falling out of the edge portion 20a of the package surface. do.

As shown in FIG. 5, several packages can be formed simultaneously. Separate strands 14 are drawn from the separate pits to form each package. The strands are wound around a single collet 22 to form a package 19. Each package is formed using a separate strand reciprocating engine having a cam 32, a cam follower 36, a strand guide 38 and a roller bale assembly 42. The packages are spaced along the collet, and the strand reciprocator is similarly aligned with the packages at intervals along the arm 56 in a similar manner.

The winding device works as follows. The strand reciprocating engine 30 guides the strands when the strands 14 are placed in a package. The strand is held in the strand guide 38 by the notch 40 and is wound around the rotating collet 22 or around the package core 26 disposed around the collet. The cam 32 is disposed near the package and rotates around an axis 33 parallel to the package axis of rotation 23. The cam follower is arranged in the cam groove 34 but does not rotate with the cam. When the cam rotates, the cam follower moves in the lateral direction parallel to the package axis of rotation 23 by the helical groove. The helical groove is continuous and has a curved end 34a that moves the cam follower in the direction and end of the package. The strand guide is attached to the cam follower and reciprocates back and forth from end to end and traverses the outer surface of the package.

The spiral winding pattern of each strand course 44 is formed by reciprocating strands across the package surface while the package is rotating. As the strand guide approaches the package edge 20a, the strand rests on the package surface below the tapered inner edge 46b of the roller. The strand guide continues to move toward the end 20c of the package, and the strand course virtually shown at the position of 44a moves between the package edge and the cylindrical edge end of the roller in contact with the package surface. As the cam follower moves the curved end 34a of the groove 34, the strand guide 38 changes direction and moves from the package edge to the package center 20b. When the strand guide changes direction, the strand course 44a is held at the edge portion 20a of the package surface because the roller bale contacts the package surface. By preventing the strand course 44a from escaping from the package edge portion 20a, a cylindrical package having an angled edge is formed.

Rotating contact between the roller and the rotating package surface rotates the roller. In general, the speed of the roller surface is equal to the speed of the package surface and the speed of the strands. If the speeds are the same, there is only a small friction force on the strand and the roller bale.

In a multiple package operation, the fiber forming process is controlled such that the formation of all packages and the increase in package radius occur at similar speeds. However, because the diameter of the strands is not always constant from package to package, there is a difference in package radius during the winding process. Due to fluctuations in blast temperature and inconsistency in material properties, the diameter of the fibers and strands can vary from package to package. Thus, the radius of one package and the other may be temporarily different until the process is complemented. The strand diameter is controlled by current injection to control the temperature of the jet. Because of the difference in package radius, the roller bales are occasionally spaced from the package surface. If the roller is not in contact with the package surface, the rotation speed of the roller starts to decrease. Then, when the surface of the roller comes in contact with the surface of the package again, the rotational speed of the roller increases until the roller surface rotates at the same speed as the package surface. Because of the small inertia of the divided roller bales, they return to their original speed more quickly than conventional heavy single roller bales that contact the package surface from end to end. Since the divided roller bales have less inertia, they slide less and generate less friction against the strands. Therefore, the possibility of breaking individual fibers in the strand is small. In addition, when the collet is accelerated, a small frictional force is generated while the divided roller bales are accelerated, so that the fiber hardly breaks.

The broken fibers, when wound on the package, are wound around a rotating roller bale that separates from the strand and creates a tangle that destroys the package. The divided rollers provide a fracture surface at which the entanglement, which is broken fibers, is comminuted. The roller includes a cylindrical end 46a forming a contact surface in contact with the edge portion 20a of the package surface 20 and a tapered end 46b not in contact with the package surface. The tapered surface extends from the contact surface to the central portion 20b of the package surface. End portion 46c of tapered surface 46b forms the fracture surface. As the strand guides move the strands from the rollers 46 to the center portion 20b of the package surface 20, the broken fibers that begin to wind around the rollers will be crushed and removed from the strands 14. Because the strands are not in contact with the rollers on the center of the package, the broken fibers are attached to the main body of the strands due to the size described above, and the entire strand is wound around the package. By the time the strand reaches another roller at the opposite package edge, the broken fiber is coalesced with the strand and the strand is wound around the package. The broken fibers do not wrap other rollers. While tapered surface 46b with edges 46c is shown, the fracture surface may also include any surface discontinuity on the roller, such as a groove or shoulder. Due to discontinuities or abrupt changes in the roller surface, the fibers will not be wound around the roller continuously and the fibers will break as the strands move across the discontinuous surface. In addition, a similar projection spaced apart from the knife edge or roller surface may be used as the fracture surface. It is preferable, but not essential, that the strands not come into contact with the roller surface immediately after the tangled fibers are crushed and removed.

As shown in FIGS. 6 and 7, the yarn or strand 68 made with the winding apparatus of the present invention is a periodic flat 70 that occurs because the roller 46 exerts pressure on the package 20. Has When the strand is placed on the rotating package, the yarn is still wet with the size coating applied by the size applicator 18. After the size has dried, the pressured portion of the strand is maintained as a flat portion in a flat shape, as shown in FIGS. 6 and 7.

Strands having at least 50 and preferably at least 200 fiber filaments typically have a major cross-sectional shape 72, which is interrupted by a periodic flat 70. Major cross-sectional phenomena depend on a number of factors, including the amount and stickiness of the size, the tension in the winding process and the number and denier of filaments in the strand. Typical fiber diameters are in the range of about 2.5 to about 13 μm, and in yardage, they range from about 2.7 to about 270 tex (grams / km) (180,000 to 1,800 yard per pound). Winding the strands under normal conditions results in a major cross-sectional shape of the somewhat flattened or elongated strands, as shown in FIG. 8. The main cross-sectional shape is the shape of the strand between the flat portions, and the main cross-sectional shape preferably has an aspect ratio in the range of about 1: 1 to about 6: 1. The aspect ratio is the long dimension or length L divided by the short dimension l. The flat portion is considerably flatter than the main cross-sectional area and, as shown in FIG. 9, preferably has a flat cross-sectional shape with an aspect ratio greater than about 6: 1. The aspect ratio of the flat part is a value obtained by dividing the long dimension or the length L 'by the short dimension l'. More preferably, the aspect ratio of the flat cross-sectional shape is greater than about 20: 1. Preferred aspect ratios of the flat cross-sectional shape are from about 6: 1 to about 50: 1. As shown in FIG. 6, the width of the flat portion 70 is considerably wider than the width of the main cross-sectional shape region. The width of the flat portion is expected to be about 5 to about 20 times the width of the main cross-sectional shape, other ratios are possible.

Since the strands or yarns of the present invention have periodic flats, they exhibit unique properties when applied or incorporated into other products or processes. Usually, the flatten is visible in some way, as visually pronounced, thereby giving the flattened characteristics unique to other parts of the yarn. Thus, the flats form “differentiated” yarns by creating another or differentiated yarn where the flats are present. For example, the flats in the yarns used to make the woven fabric are prominent because they are more reflective than the other parts of the weft, so the effect of the flats is to create a yarn that is different from the other parts.

Strands or yarns with periodic flats can be used for many purposes. One possible use is as a weft for woven fabrics of the type used as cloth for reinforcing printed circuit boards. The yarn of the present invention can be used with advantages in various industrial applications, and because of its large surface area, the flat portion exhibits great bonding force with the resin matrix. Industrial tapes will require less adhesion, providing the same adhesion between the fiberglass reinforcement and the resin. Multiple axes of nonwoven scrims, which depend on the bonding where the fibrous layers intersect, can be made stronger or with reduced binder content. The yarns of the present invention can be introduced for devices for making crushed strand mats. The yarn may also be used for beaming operations. In short, the periodic flatness of the yarn is of potential value if the combination of the yarn with another material is desired.

By controlling the length of the strand wound on the package center portion 20b, which is the area between the edge portions 20a and 20c, the length of the period P between the centers of the flat portions can be controlled, and the speed of the winding process and the package This can be done by adjusting the angle at which the strand is laid on the bed. When the winding angle or the laying down angle is made small, the rotation of the package increases between the both ends, and thus the stock price P between the flat portions becomes long. In conventional strand package processes other angles are possible, but the winding angle is generally maintained within the range of about 4 to about 9 degrees. The winding angle required for the strand to loosen well from the stable package and package will be a function of the type and weight of the strand and the type and amount of fibrous size. If the winding angle is sharp or large, the strands move quickly from one end to the other, thus shortening the period between the flat portions. The winding angle is also affected by the speed at which the strand guides reciprocate from one end to the other end. Therefore, it is possible to control the planarization of the strands by controlling the crossing speed of the strands. In a particular embodiment of the present invention, in order to provide a period P between the flat portions which are constantly fixed, the transverse speed of the strands is controlled as the diameter of the package increases.

As the strand is wound around the package, the diameter of the package increases. Since the distance the strand travels around the package increases over time, the increase in diameter also affects the period P between the flats. Typical yarn travel speeds are possible at higher speeds, but are in the range of about 100 to about 1000 m / min. One way to ensure a constant period is to adjust the winding angle as the package is formed to offset the increase in package diameter. In a preferred embodiment of the present invention, the period of the periodic flat portion is in the range of about 0.2 to about 6 m, more preferably in the range of about 0.5 to about 3 m.

The length D of the flat portion is determined by the amount of time that the strand is in the edge portion while the strand is wound in the edge portions 20a and 20c. This can be controlled by selecting a long or short contact area for the cylindrical edge end 46a of the roller 46 and providing a long or short curved end path 34a in the groove 34 of the cam 32. In general, when the cam 32 rotates slowly, the time for which the strand is present in the edge portions 20a and 20c becomes long. The length of the periodic flats is preferably in the range of about 0.5 to about 10 cm, more preferably in the range of about 1 to about 5 cm.

The width L 'of the flat portion can be controlled by adjusting the pressure of the roller 46 on the package. Applying greater pressure to the ends 20a and 20c will result in further flattening. In normal operation, the roller 46 accommodates the size of the package that is increased away from the collet 22. The magnitude of the pressure exerted by the rollers on the package can be increased by increasing the initial pressure exerted by the rollers and maintaining the pressure during the package process. In addition, the pressure may be increased by reducing the amount of withdrawal of the arm 56 during the package process. Various methods can be used to control the pressure of the roller bale on the package, including a computer controlled motor for moving the mounting arm 56 according to a predetermined plan. The pressure of the roller can be controlled to obtain as much flatness as desired in the flat portion.

As shown in FIG. 10, the package 19 is supported by its end, and the periodically flattened strand 68 is released from the inside of the package. The package is supported by itself. That is, the pulley is supported by itself without collapse during the process.

In general, the outer surface 20 of the package consists of a central portion 20b which is a curved surface and two annular plateaus 74 formed at the ends 20a and 20c by the flattening effect of the rollers. The central portion 20b of the package is a slightly sloped curved surface whereas the plateau is generally parallel to the longitudinal axis of the package. The width of the plateau is affected by the amount of pressure applied to the roller. The pressure exerted on the package by each roller is generally in the range of about 2 to about 10 pounds (0.91 to 4.5 kg), preferably in the range of about 3 to about 6 pounds (1.4 to 2.7 kg).

The flat portion 70 of the strand is located only at the ends 20a and 20c of the package. The increased surface area of the flats affects the construction of the package by increasing the bond or cohesive contact between any particular course of the strand and the adjacent course. The bond strength is greater than the bond strength of strands having a major cross-sectional shape. The bonding force may be increased, resulting in the need to adjust the amount of size applied to the strand or the adhesive properties of the size. If the engagement of the strands is excessively large, the strands 68 will not easily loosen from the package. If the bond is too weak, the loose strand may loosen, swell or otherwise get tangled too easily. The average tension or force required to loosen the strand is preferably in the range of about 5 to about 100 g.

As shown in FIGS. 11 and 12, the yarns or strands 68 of the present invention may be used in woven fabric 78 on loom 80. The loom can be an air jet loom or any other type of loom, as shown. The looms are supplied with warp yarns 84 and 86, and the strands 68 of the present invention are inserted into the fabric as weft yarns. Operation of looms for making fabrics is known to those skilled in the art. Air jet 82 picks or propels the weft or strand 68 between the sheds of the upper and lower warp yarns. Reed 88 strikes or pushes the weft and warp to form a fabric and may be wound or moved by any suitable means, such as drum 90. As shown in FIG. 12, two wefts 68 may be supplied to the air jet, and two separate air input lines 92 may be provided so that the wefts may be alternately supplied from the nozzle 94. The lid 88 is provided with a series of air jets (not shown) to help move the weft across the width of the loom.

In air jet looms, the use of the yarns of the present invention is that yarns with periodic flats may increase the air drag when the flats are affected by air blasts and air jets on the leads from the air jet nozzles. This allows the machine to operate more efficiently. In certain embodiments of the present invention, the flats may be synchronized to allow the flats to pass through the air jet in the initial stage of pushing the weft across the air jet loom, the synchronization being optional. While weaving and weaving processes illustrate the yarns of the invention as wefts, the yarns of the invention can also be used as warp yarns.

One of the features of the winding apparatus of the invention is that the contact of the roller bales on the package makes it possible to produce a relatively large diameter package. In addition, the ratio of the axial length of the package to the diameter can also be increased. The axial length of the package can be any length desired, but is preferably in the range of about 8 to about 40 cm. Preferably, the diameter is in the range of about 20 to about 50 cm. Increasing the engagement of the strands at the ends of the package provides a package that is more stable, i.e., can be wound with a relatively short axial length and a relatively large diameter. This is an advantage in the strand manufacturing process because it is possible to manufacture a large number of packages with a significant amount of strands.

As shown in FIG. 13, the fabric 78 includes warp yarns 84, 86. The weft yarn is marked 96 in the yarn and includes a flat portion that is differentiated from the remaining portion 98 of the weft yarn. Differentiated yarns can be formed into a patterned fabric as shown. Differentiated yarns differ primarily from the remainder of the yarn in their visual appearance. For example, the differentiated yarn may be lighter or darker in color than the remaining yarns. Differentiated yarns may cause more reflection than residual yarns. Differentiated yarns may be wider than the remaining yarns, and may have an average width in the range of about 125 to about 300% of the average width of the remaining yarns in the weft, preferably in the range of about 125 to about 175% of the average width of the remaining wefts. . The average length of the differentiated wefts is preferably in the range of about 0.5 to about 10 cm, more preferably in the range of about 1 to about 5 cm.

As shown in FIG. 14, the differentiated yarns can form a decorative pattern in a fabric. FIG. 15 allows differentiated wefts to be aligned to a particular warp 100 to form a longitudinal pattern along the length of the fabric. As shown in FIG. 16, the differentiated yarns may be placed at any interval throughout the fabric.

The principles and manners of the present invention have been described in the preferred embodiments. However, it can be implemented within the scope without departing from the spirit of the present invention.

The present invention may be useful for packaging, dispensing and weaving yarns for strength enhancement.

Claims (100)

14. A strand of individual filaments characterized in that it has a main cross-sectional shape and a periodic flat portion of a flat cross-sectional shape extending from said main cross-sectional shape. The method of claim 1, Wherein said major cross-sectional shape has an aspect ratio in the range of about 1: 1 to about 6: 1, and said flat cross-sectional shape has an aspect ratio greater than about 6: 1. The method of claim 2, And wherein said aspect ratio of said flat cross-sectional shape is greater than about 20: 1. The method of claim 2, And the aspect ratio of said flat cross-sectional shape is in the range of about 6: 1 to about 50: 1. The method of claim 1, Wherein the width of said flat portion is in the range of about 5 to about 20 times the width of said major cross-sectional shape. The method of claim 1, Wherein the period of said periodic planar portion is in a range from about 0.2 to about 6 m. The method of claim 6, And wherein the period of said periodic planar portion is in a range from about 0.5 to about 3 m. The method of claim 1, And wherein said periodic planar portion is in the range of about 0.5 to about 10 cm in length. The method of claim 8, And wherein said periodic planar portion has a length in the range of about 1 to about 5 cm. A strand of individual filaments having a main cross-sectional shape and a periodic flat portion having a flat cross-sectional shape extending beyond the main cross-sectional shape, wherein the period of the periodic flat portion is in the range of about 0.2 to about 6 m, and the main cross-sectional shape is about 1 And an aspect ratio in the range of from 1: 1 to about 6: 1, wherein the flat cross-sectional shape has an aspect ratio greater than about 6: 1. The method of claim 10, And wherein said aspect ratio of said flat cross-sectional shape is greater than about 20: 1. The method of claim 10, And the aspect ratio of said flat cross-sectional shape is in the range of about 6: 1 to about 50: 1. The method of claim 10, Wherein the width of the flat portion is in the range of about 5 to about 20 times the width of the major cross-sectional shape. The method of claim 10, And wherein the period of said periodic planar portion is in a range from about 0.5 to about 3 m. The method of claim 10, And wherein said periodic planar portion is in the range of about 0.5 to about 10 cm in length. The method of claim 15, And wherein said periodic planar portion has a length in the range of about 1 to about 5 cm. A strand having at least 50 glass fiber filaments, said strand having a periodic cross-section having a major cross-sectional shape and a flat cross-sectional shape extending from said main cross-sectional shape. The method of claim 17, Wherein said major cross-sectional shape has an aspect ratio in the range of about 1: 1 to about 6: 1, and said flat cross-sectional shape has an aspect ratio greater than about 6: 1. The method of claim 17, Wherein the width of the flat portion is in the range of about 5 to about 20 times the width of the major cross-sectional shape, and the length of the periodic flat portion is in the range of about 0.5 to about 10 cm. The method of claim 17, Wherein the period of said periodic planar portion is in a range from about 0.2 to about 6 m. The process of winding the strand to the package by rotating the collet, the process of winding the strand in a spiral pattern on the package by crossing the strand from one end to the other end of the package, contacting the roller bale and the package at the edge of each end of the package Pressurizing the package with the roller bale to flatten the strand as it is wound at the edge, thereby forming a strand having a periodic flat portion, and controlling the pressure of the roller bale on the package to control the pressure of the strand. And a process for controlling planarization. The method of claim 21, And the roller bale is spaced apart from the collet while winding the strand to accommodate the increase in the package diameter. The method of claim 21, And the pressure exerted on the package by each of the rollers is in the range of about 2 to about 10 pounds (0.91 to 4.5 kg). The method of claim 23, And the pressure exerted on the package by each of the rollers is in the range of about 3 to about 6 pounds (1.4 to 2.7 kg). Rotating the collet to wind the strand into the package, traversing the strand from one end of the package to the other end and winding the strand in a spiral pattern on the package, the roller bale at the edge of each end of the package and the end of the package Contacting, pressing the package with the roller bale, the strand is flattened when the strand is wound at the edge portion, forming a strand having a periodic flat portion, and controlling the transverse speed of the strand And a process for controlling the planarization of the strands. The method of claim 25, Controlling the length of the flat portion by controlling the transverse velocity of the strand to determine the length of winding the strand on the package while the strand is at the edge portion. The method of claim 25, And a cycle of the flat part is controlled by changing a transverse speed of the strand during winding. The method of claim 25, A strand collecting method, characterized in that to provide a generally constant period between the flat portions by controlling the traverse speed of the strand. The method of claim 26, And a cycle of the flat part is controlled by changing a transverse speed of the strand during winding. The method of claim 26, A strand collecting method, characterized in that to provide a generally constant period between the flat portions by controlling the traverse speed of the strand. The method of claim 25, The strand is traversed by a reciprocating movement of a strand reciprocating engine mounted to move along a spiral groove in a rotating cam, the spiral groove having a curved end at each end of the cam, and the transverse speed of the strand being a curved surface of the spiral groove. The strand collecting method is controlled by constructing the shape of the end portion. The method of claim 31, wherein And a cycle of the flat part is controlled by changing a transverse speed of the strand during winding. The method of claim 31, wherein A strand collecting method, characterized in that to provide a generally constant period between the flat portions by controlling the traverse speed of the strand. The method of claim 32, A strand collecting method, characterized in that to provide a generally constant period between the flat portions by controlling the traverse speed of the strand. The process of winding the strand to the package by rotating the collet, the process of winding the strand in a spiral pattern on the package by crossing the strand from one end to the other end of the package, contacting the roller bale and the package at the edge of each end of the package By pressing the package with the roller bale, the strand is flattened when the strand is wound at an edge, thereby forming a strand having a periodic flat portion, and the pressure of the roller bale on the package and the And controlling a flattening of the strand by controlling a transverse speed. 36. The method of claim 35 wherein Wherein the pressure exerted on the package by each roller is in the range of about 2 to about 10 pounds (0.91 to 4.5 kg). 36. The method of claim 35 wherein And a cycle of the flat part is controlled by changing a transverse speed of the strand during winding. The method of claim 36, And a cycle of the flat part is controlled by changing a transverse speed of the strand during winding. 36. The method of claim 35 wherein A strand collecting method, characterized in that to provide a generally constant period between the flat portions by controlling the traverse speed of the strand. 36. The method of claim 35 wherein And the roller bale is spaced apart from the collet while winding the strand to accommodate the increase in the package diameter. A process for propelling the weft yarn from the insertion side of the loom to the outlet side by one or more air jets, wherein the weft thread is inserted on the air jet loom, wherein the weft yarn has strands of individual filaments, and the strand And a periodic flat portion having a cross-sectional shape and a flat cross-sectional shape extending from the main cross-sectional shape, wherein the flat portion provides an increased drag against propulsion by the air jet. 42. The method of claim 41 wherein Weft insertion method, characterized in that the period of the flat portion is synchronized with the length of the weft yarn required for the air jet loom. The method of claim 42, When pushing the weft across an air jet loom, the weft inserting method characterized in that the flat part is synchronized such that the flat part passes through the air jet. 42. The method of claim 41 wherein And wherein said major cross-sectional shape has an aspect ratio within a range from about 1: 1 to about 6: 1, and said flat cross-sectional shape has an aspect ratio greater than about 6: 1. The method of claim 44, And an aspect ratio of said flat cross-sectional shape is greater than about 20: 1. The method of claim 44, And the planar cross-sectional shape has an aspect ratio in the range of about 6: 1 to about 50: 1. 42. The method of claim 41 wherein Weft insertion method, characterized in that the width of the flat portion is in the range of about 5 to about 20 times the width of the main cross-sectional shape. 42. The method of claim 41 wherein Weft insertion method, characterized in that the length of the flat portion is in the range of about 0.5 to about 10 cm. 49. The method of claim 48 wherein Weft insertion method, characterized in that the length of the flat portion is in the range of about 1 to about 5 cm. 42. The method of claim 41 wherein Weft insertion method, characterized in that the period of the flat portion is in the range of about 0.2 to about 6 m. 51. The method of claim 50 wherein Weft insertion method, characterized in that the period of the flat portion is in the range of about 0.5 to about 3 m. A process for propelling the weft yarn from the insertion side of the loom to the exit side by one or more air jets, wherein the weft yarn is inserted onto the air jet loom, wherein the weft yarn has strands of individual filaments, the strands being approximately Having a major cross-sectional shape having an aspect ratio in the range of 1: 1 to about 6: 1, wherein the strand has a periodic flat portion having a flat cross-sectional shape having an aspect ratio greater than about 6: 1, the flat portion being propelled by the air jet Weft insertion method, characterized in that for providing an increased drag. The method of claim 52, wherein Weft insertion method, characterized in that the period of the flat portion is synchronized with the length of the weft yarn required for the air jet loom. The method of claim 53, wherein When pushing the weft across an air jet loom, the weft inserting method characterized in that the flat part is synchronized such that the flat part passes through the air jet. The method of claim 52, wherein And an aspect ratio of said flat cross-sectional shape is greater than about 20: 1. The method of claim 54, wherein And the aspect ratio of said flat cross-sectional shape is in the range of about 6: 1 to about 50: 1. The method of claim 52, wherein Weft insertion method, characterized in that the width of the flat portion is in the range of about 5 to about 20 times the main cross-sectional shape. The method of claim 52, wherein Weft insertion method, characterized in that the length of the flat portion is in the range of about 0.5 to about 10 cm. The method of claim 52, wherein Weft insertion method, characterized in that the period of the flat portion is in the range of about 0.2 to about 6 m. A process for propelling the weft yarn from the insertion side of the loom to the exit side by one or more air jets, wherein the weft yarn is inserted onto the air jet loom, wherein the weft yarn has strands of individual filaments, the strands being approximately Having a major cross-sectional shape having an aspect ratio within a range from 1: 1 to about 6: 1, wherein the strand has a periodic flat portion having a flat cross-sectional shape having an aspect ratio within a range from about 6: 1 to about 50: 1, and the width of the flat portion The range of about 5 to about 20 times the width of the main cross section detective, the length of the flat portion is within the range of about 0.5 to about 10 cm, the period of the flat portion is within the range of about 0.2 to about 6 m, Weft insertion method, characterized in that for providing an increased drag for propulsion by the air jet. A woven fabric of warp and weft yarns, the weft yarns comprising strands of individual filaments, the strands having a periodic cross section of a main cross-sectional shape and a flat cross-sectional shape extending from the main cross-sectional shape, wherein the effect of the flat portion is a woven fabric Weaving fabric, characterized in that the weft of the differentiation. 62. The method of claim 61, Weaving fabric, characterized in that said differentiated weft is lighter in color than said residual weft. 62. The method of claim 61, And the differentiated warp produces more reflection than the remaining warp. 62. The method of claim 61, Weaving fabric, characterized in that the different weft yarn is wider than the remaining weft yarn. The method of claim 64, wherein And said differentiated weft yarn has an average width in the range of about 125 to about 300% of the average width of said residual weft. 66. The method of claim 65, And the differentiated weft yarn has an average width in the range of about 125 to about 175% of the average width of the residual weft. 62. The method of claim 61, Weaving fabric, characterized in that the average length of the differentiated weft is in the range of about 0.5 to about 10 cm. The method of claim 67 wherein Weaving fabric, characterized in that the length of the differentiated weft is in the range of about 1 to about 5 cm. 62. The method of claim 61, Weaving fabric, characterized in that the different wefts are arranged at randomly generally throughout the fabric. 62. The woven fabric of claim 61, wherein said differentiated wefts are aligned with particular warp yarns to form a longitudinal pattern along the length of the fabric. 62. The method of claim 61, Weaving fabric, characterized in that the different weft forming a repeating pattern in the fabric. A woven fabric of warp and weft yarns, the weft yarns comprising strands of individual filaments, the strands having a periodic cross section of a main cross-sectional shape and a flat cross-sectional shape extending from the main cross-sectional shape, wherein the effect of the flat portion is a woven fabric Differentiated weft yarns, wherein the differentiated wefts are wider than the remaining wefts and have an average length in the range of about 0.5 to about 10 cm, wherein the differentiated wefts have an average width in the range of about 125 to about 300% of the average width of the remaining wefts Woven fabric, characterized in that having. The method of claim 72, And the differentiated warp produces more reflection than the remaining warp. The method of claim 72, Weaving fabric, characterized in that the different wefts are arranged at randomly generally throughout the fabric. A woven fabric of warp and weft yarns, wherein the warp yarns have strands of individual filaments, the strands having a periodic cross-section having a major cross-sectional shape and a flat cross-sectional shape extending from the main cross-sectional shape, wherein the effect of the flat portion is a woven fabric Woven fabrics, characterized in that the distinctive warp. 76. The method of claim 75 wherein And said differentiated warp is brighter in color than said residual warp. 76. The method of claim 75 wherein And the differentiated warp produces more reflection than the remaining warp. 76. The method of claim 75 wherein And the differentiated warp has an average width in the range of about 125 to about 300% of the average width of the remaining warp. 76. The method of claim 75 wherein Weaving fabric, characterized in that the average length of the differentiated warp is in the range of about 0.5 to about 10 cm. 76. The method of claim 75 wherein Weaving fabric, characterized in that the differentiated warp is disposed at any interval generally throughout the fabric. A package of self-supporting spirally wound yarns suitable for pulling and unwinding yarns without collapse of the package, the yarns having strands of individual filaments, the strands being flat extending over the main cross-sectional shape and the main cross-sectional shape And a periodic flat portion having a cross-sectional shape, the package having an edge portion axially located at an end of the package, wherein the flat portion is located within an edge portion of the package. 82. The method of claim 81 wherein The package is wound into a spiral course, the size is applied to the yarns, the size joins each course and the adjacent course, and the flat portion exhibits a stronger bond than the portion having the main cross-sectional shape of the yarn. . 82. The method of claim 81 wherein And the package has an axial length in the range of about 8 to about 40 cm. 82. The method of claim 81 wherein And wherein said package has a diameter in the range of about 20 to about 50 cm. 82. The method of claim 81 wherein Wherein said package has an axial length in the range of about 8 to about 40 cm and a diameter in the range of about 20 to about 50 cm. 82. The method of claim 81 wherein Wherein the average force required to unwind the yarn from the package is in the range of about 5 to about 100 g. 82. The method of claim 81 wherein Wherein said yarn has a diameter in the range of about 2.5 to about 13 μm. 82. The method of claim 81 wherein And wherein the period of said periodic planar portion is in a range from about 0.2 to about 6 m. 89. The method of claim 88 wherein And wherein the period of said periodic planar portion is in a range from about 0.5 to about 3 m. 82. The method of claim 81 wherein And the periodic flat portion has a length in a range from about 0.5 to about 10 cm. 92. The method of claim 90, And the periodic flat portion has a length in the range of about 1 to about 5 cm. A package of self-supporting spirally wound yarns suitable for pulling and unwinding yarns without collapse of the package, the yarns having strands of individual filaments, the strands being flattened over the major cross-sectional shape and the major cross-sectional shape A periodic flat portion having a cross-sectional shape, the package having an edge portion located at the end of the package in a stall, the flat portion being located at an edge portion of the package, the period of the periodic flat portion being within a range of about 0.2 to about 6 m. And wherein said periodic flat portion has a length in a range from about 0.5 to about 10 cm. 92. The method of claim 92, The package is wound in a spiral course, a size is applied to the yarns, the size joins each course to an adjacent course, and the flat portion exhibits a stronger bond than the portion having the main cross-sectional shape of the yarn. package. 92. The method of claim 92, And the package has an axial length in the range of about 8 to about 40 cm. 92. The method of claim 92, And wherein said package has a diameter in the range of about 20 to about 50 cm. 82. The package of claim 81, wherein the package has an axial length in the range of about 8 to about 40 cm and a diameter in the range of about 20 to about 50 cm. 92. The method of claim 92, Wherein the average force required to unwind the yarn from the package is in the range of about 5 to about 100 g. 82. The method of claim 81 wherein And wherein said yarn has a diameter in the range of about 2.5 to about 13 μm. 92. The method of claim 92, Wherein the period of the periodic flat is in the range of about 0.5 to about 3 m and the length of the periodic flat is in the range of about 1 to about 5 cm. A package of self-supporting spirally wound yarns suitable for unwinding by pulling the yarns without collapse of the package, the yarns having strands of individual filaments, the strands extending beyond the main cross-sectional shape and the main cross-sectional shape. A periodic cross-section having a flat cross-sectional shape, the package having an edge portion circumferentially disposed at an end of the package, the flat portion being located at an edge portion of the package, wherein the periodic flat portion has a period of about 0.2 to about 6 m. Within the range, wherein the length of the periodic flat is in the range of about 0.5 to about 10 cm, and the package has an axial length in the range of about 8 to about 40 cm and a diameter in the range of about 20 to about 50 cm, A package characterized in that the average force required to loosen the yarn is in the range of about 5 to about 100 g.